SHERCO ST 125, Workshop Manual

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1
TABLE OF CONTENTS
FOREWORD .................. Erreur ! Signet non défini.
ST SERIES TOOLS LIST .. Erreur ! Signet non défini.
TECHNICAL SHEETS ...... Erreur ! Signet non défini.
ENGINE ............................................................... 4
CYCLE PARTS .................................................. 5
ORIGINAL SETTINGS ......
Erreur ! Signet non défini.
CARBURETOR ..................................................... 6
FRONT FORK....................................................... 7
REAR SHOCK ................ Erreur ! Signet non défini.
CYCLE PARTS ..................................................... 8
FRONT ................................................................ 8
1.1 Wheel bearing replacement ............................................ 8
1.2 Disc replacement ......................................................... 8
1.3 Fork disassembly ......................................................... 9
1.4 Fork maintenance ...................................................... 10
REAR ................................................................ 13
2.1 Wheel bearing replacement ......................................... 13
2.2 Disc replacement ....................................................... 13
2.3
Swingarm bearing control ............................................ 14
2.4 Control of links ........................................................... 15
OPERATIONS REQUIRING REMOVAL OR NOT OF
THE ENGINE
............................................................. 16
ENGINE REMOVAL / ASSEMBLY .................. 17
ENGINE REMOVAL ......................................... 17
ENGINE ASSEMBLY ....................................... 17
DISASSEMBLY OF THE ENGINE ................... 18
❱❘ Oil draining ............................................................. 18
❱❘ Removal of pinion and selector .............................. 18
❱❘ Removing the cylinder head, cylinder and piston .. 19
❱❘ Removing the clutch cover ..................................... 20
❱❘ Clutch and primary gear removal ........................... 21
❱❘ Kick removal ........................................................... 21
❱❘ Removal of the selection ........................................ 22
❱❘ Removing the ignition ............................................. 23
❱❘ Intake pipe and reed box ........................................ 23
❱❘ Removal stator ....................................................... 24
❱❘ Separate the crankcase ......................................... 24
❱❘ Removing the gear box .......................................... 25
❱❘ Removing the connecting rod assembly ................ 26
ENGINE ELEMENT CONTROL ....................... 27
❱❘ Balance weight, external dimension control ........... 27
❱❘ Connecting rod radial clearance ............................ 27
❱❘ Connecting rod head side play ............................... 27
❱❘ Crankshaft runout control ....................................... 27
❱❘ Piston ..................................................................... 28
❱❘ End gap .................................................................. 28
❱❘ Piston pin check ..................................................... 28
❱❘ Piston / cylinder condition check ............................ 29
❱❘ Reed box, inlet pipe ............................................... 29
❱❘ Clutch ..................................................................... 30
❱❘ Clutch disc control .................................................. 30
❱❘ Gear box ................................................................. 31
REASSEMBLING THE ENGINE ...................... 32
❱❘
Assembly of crankcase .......................................... 32
❱❘ Ignition assembly ................................................... 32
❱❘ Selection mechanism ............................................. 33
❱❘ Kicker shaft mounting ............................................. 34
❱❘ Primary transmission and clutch ............................ 34
❱❘ Clutch cover ........................................................... 36
❱❘ Water pump cover .................................................. 36
❱❘ Piston / cylinder ..............
Erreur ! Signet non défini.
❱❘ Squish tabke setting ............................................... 37
❱❘ head cylinder .......................................................... 37
❱❘ Reed box, inlet pipe ............................................... 38
❱❘ Front sproket .......................................................... 38
TIGHTENING TORQUES TABLE ....................39
ELECTRICAL PART ........................................40
❱❘ Electrical components ............................................ 40
❱❘ Ignition stator control .............................................. 41
❱❘ Hall sensor control ................................................. 41
❱❘ Regulator ................................................................ 41
❱❘ CDI ......................................................................... 42
❱❘ Ignition coil ............................................................. 42
❱❘ Temperature sensor ............................................... 43
❱❘ Fan ......................................................................... 43
ELECTRIC DRAWING .....................................44
❱❘ Homologated light harness .................................... 44
❱❘ Racing light harness ............................................... 46
❱❘ Principal harness ..................................................... 47